MAAGTM WPU two-stage gear

unit for coal mills

Our quality policy

FLSmidth MAAG Gear is committed

to creating strong relationships with
customers, suppliers and employees that establish us as a trustworthy, reliable and professional partner.
This commitment includes providing high-quality and high-value solutions, products and services that
create satisfied and loyal customers.
We are certified to the ISO 9001:2008
standards. With our process manage
ment we endeavor to meet and exceed
international quality standards and provide adequate resources to support the
quality system. Our quality policies are
centered on the importance of meeting
our customers requirements.
The quality objectives are continuingly established and reviewed by
our management. Our employees are
committed to the companys management system and to the continual
improvement of the system and the

entire organization. Each employee is aware of the vision and strategy of FLSmidth MAAG Gear, and
works in a culture of opportunity.
With our suppliers and external partners we cultivate an open
communication and work on performance-oriented results.

A pioneer of modern
gear technology
FLSmidth MAAG Gear has almost
100 years of experience in manufacturing gear units. The company was
founded in 1913 and quickly expanded into an international group. FLSmidth MAAG Gear introduced the
technology of mill gear units for the
cement industry with great success in
1966. Since then over 700 MAAGTM
gear units were sold in this sector.
The company
At the FLSmidth MAAG Gear headquarters in Winterthur, Switzerland,
more than 100 employees work in
development, design, finance, project
management, sales, customer service and marketing. Production takes
place in two modern plants equipped
with high-performance machines. In
Elblag/Poland and Milano/Italy more
than 200 employees manufacture
gear units, drive systems and components which satisfy the most demanding quality standards. The company
belongs to the successful FLSmidth
Group, a listed Danish firm.
Our strength
The combination of unique precision,
accuracy and modularized solutions
with compact design are leading to
high efficiency products and therefore
low maintenance cost for the customer. Experience, new technical solutions
and the latest manufacturing techniques are regularly incorporated into
the production process.
Intensive development and training
of our engineers assure best understanding of how to operate a gear
unit and lengthen its life cycle.

A constant willingness to innovate,

and close collaboration with our customers have helped to ensure that
MAAG gear units continue to operate
reliably throughout the world under
the toughest conditions.
Product range
Today, the product range includes
various gear units for mills, complete drive systems, gear solutions
for bucket wheel excavators and belt
conveyors, as well as maintenance
systems for all types of plant. In addition FLSmidth MAAG Gear manufactures components such as bevel sets,
girth gears and various replacement
parts.
All MAAG gear units are available as
standard solutions or are customized
to the required needs.

Innovative technology

Introduction
The compact two-stage MAAGTM
gear bevel and planetary gear unit
transmits the power from the electric
motor to the grinding table. It reduces
the speed of the electric motor to the
desired speed of the grinding table
and changes the horizontal input axis
to a vertical output axis. The gear
unit also supports the grinding table,
mounted on the output disc. An
external oil supply unit lubricates and
cools the gear unit.
FLSmidth MAAG Gear distributes
two MAAG WPU series based on the
same design concept. The smaller
MAAG WPU series from type 01 to
59 described here is focused on coal
mills in the cement and thermal
power plant industry. For more
information about the MAAG WPU
series for vertical cement mills from
type 54 to 420 please refer to our
separate brochure.
Assemblies
Thrust bearing grinding table with
associated casing. Planetary gear
stage with internally toothed ring
gear. Bevel gear stage mounted in
bottom casing. Application of roller
bearings on toothed parts ensures
precise transmission.

Gearing
Both bevel and planetary stage gears
are made from very high-quality
materials, precisely cut on top class
machines and heat treated in fully
controlled equipment. The toothed
flanks of the sun pinions have both
profile and longitudinal modifications
to fully compensate for deformations
of the sun pinion and planet wheels
occurring under load. This method
guarantees optimum tooth flank con
tact and very long life cycle.
Drive
The motor drives the bevel gear stage
via a flexible coupling. The torque
is then transmitted to the planetary
gear stage via a toothed coupling.
The rotating planet carrier is bolted
and pinned to the output disc and
drives the grinding table.
Thrust bearing
The pads of the high-quality tiltingpad thrust bearing for the grinding
table are lined with babbitt metal.
Their purpose is to absorb the static
and dynamic grinding forces. They
are of hydrodynamic type lubricated
by low-pressure pumps or hydrostatic
type on demand. Their temperature
is continuously monitored.

Customer benefits
High operational reliability
Customer-specific design
of gear units
Very high efficiency

Planetary gear stage and thrust

bearing for grinding table
with a very long service life
Short installation time
Low-cost maintenance

Casing with internally toothed

ring gear
The gear casing consists of a robust
welded steel construction or wellribbed cast structure. The fixed ring
gear is mounted to the casing so
that reliable torque transmission is
guaranteed. The grinding load in
cluding grinding table weight is
transmitted straight to the foundation via the tilting-pad thrust bearing
and the casing wall (see Fig. 1).
Coupling
Our standard supply includes a flexible coupling with the following features:
Durable and reliable
Low operating costs
Almost maintenance-free
(no lubricants to change)
Low vibratory loads in the drive
train
Relatively wide range for axial
and radial misalignment

Planet shafts
The planet shafts are made from
alloy steel. Spherical roller bearings,
mounted on them, ensure best possible position of planet wheel during
operation in each load condition.
Lubrication system
The gear unit is lubricated by a closed
circuit oil system. The oil tank serves
as a platform on which all the assemblies and components such as motor pumps (high and low pressure),
switchable double oil filter, oil cooler
and instrument panel are installed.
The design of the lubrication system
is standardized thus it is applicable
for several gear types. This ensures
easy handling, optimal insertion and
low costs. Also the components of
the lubrication system like instrumentation, filter and cooling/ heating system are consistent. The lubrication
system is monitored with digital indication on site. Top priority is given

Figure 1

to guarantee operational reliability. A

lubrication system with high pressure
pump is available if required by the
application.
Instrumentation
To ensure highest reliability and lowest maintenance costs, gear and
lubrication unit are equipped with
sensors, which monitor operation
parameters like bearing temperature,
oil pressure or vibration level. On demand the entire electrical equipment
installed on the gear unit complies
with anti-explosive requirements.
Auxiliary drive/maintenance
drive
Auxiliary or maintenance drives are
available to meet your demands. The
maintenance drive is placed between
the mill motor and the gear unit,
whereas the auxiliary drive is located
behind the mill motor.

MAAGTM WPU series for coal mills

Type

P/n
(kW/rpm)

Fa
(kN)

D
(mm)

H
(mm)

Weight
(t)

04

3,8

558

1100

1100

4,5

06

5,0

675

1220

1100

08

6,6

951

1380

1215

6,5

12

11,3

10001600

15301700

12301475

9,511,7

19

16,5

15001950

17001830

13701420

12,714

27

24,6

17502376

19502200

15151700

1721,7

37

34

23003300

20002470

17401980

1937

48

43,00

31603350

23402520

19602090

2432,5

Fields of application
The smaller MAAG WPU series is
widespread and well proven in coal
mills used in
Cement plants
Power plants

Cement plant

Power plant

Hazardous environments
The coal grinding system must take
into account the available heat sources
for drying the raw coal as well as the
fire and explosion hazards of coal
dust. The entire grinding plant must
therefore be shock-resistant and
equipped with a number of explosion
relief valves.

On demand FLSmidth MAAG Gear

will follow the latest ATEX standards
mainly asked for in thermal power
plant applications.

Customer benefits

Condition Monitoring
To ensure highest reliability and
lowest maintenance costs, the gear
unit is equipped with diagnostic
tools and sensors monitoring all
important operation parameters.
Customer service
Customer service staff is highly
trained and guarantees professional support in routine and
emergency services, gear unit inspections, overhaul or assembly.

Service Hotline
24 hrs/day 7 days/week
+41 79 619 91 00
service@FLSmidthMaagGear.com
Spare parts
Spare parts are available throughout the life of the gear units.
Test running
Gear units are tested and logged
in detail on our test bed prior to
delivery.

Delivery time
Thanks to continuous monitoring
of our production schedule, our
clients are provided with the up-todate status of a project at any time.

Training
FLSmidth MAAG Gear offers training programs for local maintenance personnel to enable them
to keep the gear units in shape.

Installation
The compact design simplifies shipping and reduces erection time.

Troubleshooting
FLSmidth MAAG Gear field service
technicians are strategically located
around the world to minimize response time and reduce costs.

Production
The latest machines and technical
aids are used in manufacturing.
Quality
Production and all activities are
monitored by the internal quality
assurance system in strict compliance with ISO 9001.

FLSmidth Atox mill with MAAGTM coal mill gear unit

FLSmidth MAAG Gear AG

Lagerhausstrasse 11 P.O. Box
8401 Winterthur Switzerland
Tel +41 52 260 35 00
Fax +41 52 260 35 35
info@FLSmidthMaagGear.com

www.FLSmidthMaagGear.com

C 11-11 500-12-ENG V1

Copyright 2011 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth, MAAG and WPU are (registered) trademarks of FLSmidth A/S.
This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this
brochure are for general reference only and may change at any time.